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Bureau of Mines Information Circular/1982 




Computerized, Remote Monitoring 
Systems for Underground Coal Mines 

Fires and Explosive Atmospheres 
By Jeffrey H. Welsh 




UNITED STATES DEPARTMENT OF THE INTERIOR 



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Information Circular 8875 



Computerized, Remote Monitoring 
Systems for Underground Coal Mines 

Fires and Explosive Atmospheres 
By Jeffrey H. Welsh 





UNITED STATES DEPARTMENT OF THE INTERIOR 
James G. Watt, Secretary 

BUREAU OF MINES 
Robert C. Norton, Director 



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This publication has been cataloged as follows: 



Welsh, Jeffrey H 

Computerized, remote monitoring systems for underground 
coal mines: fires and explosive atmospheres. 

(Information circular ; 8875) 

1. Coal mines and mining— Fires and fire prevention. 2. Mine 
safety— Equipment and supplies. I. Title. II. Series: Information 
circular (United States. Bureau of Mities) ; 8875. 



TN295.tF44TN315] 622s [622 '.8] 81-607584 AACR2 






1) 



CONTENTS 



Page 



Abstract 1 

Introduction 1 

Applications 2 

Needs for early detection 2 

Comparison of safety regulations 3 

lOlC petitions 4 

Analysis of regulations 5 

Conclusions 9 

TABLE 

1. Analysis of regulations 6 



COMPUTERIZED, REMOTE MONITORING SYSTEMS FOR UNDERGROUND COAL MINES 

Fires and Explosive Atmospheres 
By Jeffrey H. Welsh 1 



ABSTRACT 



This report presents a study on the 
use of computerized, continuous remote 
monitoring systems for fire and explosive 
atmosphere safety in underground coal 
mines. The effects of these systems on 



the safety level in mines are investi- 
gated, and the relationship between mine 
safety regulations and computerized, con- 
tinuous, remote monitoring is analyzed. 



INTRODUCTION 



Computerized, continuous, remote 
mine monitoring systems (CCRMMS) have the 
potential for improving safety in under- 
ground coal mines, as well as increasing 
production and productivity. Commer- 
cially available equipment exists to mon- 
itor most mine parameters affecting fire 
and explosive atmosphere safety. Sensors 
are available that detect methane, carbon 
monoxide, and airflow. To analyze data 
from these sensors, microprocessor-based 
computers are on the market that can 
manipulate data and transmit information 
at high speed. 

Each mine's physical characteristics 
and problems are different; therefore, 
the needs for mine monitoring systems 
are unique for each specific case. For 

^Operations research analyst, Pittsburgh 
Research Center, Bureau of Mines, 
Pittsburgh, Pa. 



example, gassy mines with severe meth- 
ane problems must maintain adequate 
ventilation throughout the mine to dilute 
methane accumulations, and operators may 
need to monitor the status of the fans, 
air velocity, and methane concentration 
to insure that safe conditions are main- 
tained. Mines working high-volatile coal 
seams may need a system for rapid detec- 
tion and location of fires. Mines with 
bad roof conditions may require detection 
and location of roof falls before they 
become a serious problem to the ventila- 
tion system. MDnitoring the environment 
for these parameters not only has a 
safety implication but also has a bene- 
ficial impact on production, since proper 
use of the information may avoid costly 
mine shutdowns and production delays. 
Once a monitoring system is in place, it 
can also be used for other purposes such 
as production monitoring, energy manage- 
ment, and maintenance control. 



APPLICATIONS 



A brief examination of how CCRMMS 
are being used at several mining 
conpanies in the United States follows. 
Example A2 has nines with greater than 
2,000 ft overburden, that are very gassy 
and have difficult roof control problems. 
Because of this situation, the com- 
pany has petitioned the Mine Safety and 
Health Administration (MSHA) , and has 
received permission to use the belt 
haulageway for intake air to ventilate 
the face, providing it continuously 
monitors for CO in the belt haulage- 
way. The company has installed 
variable-pitch ventilation fans and 
intends to monitor methane and airflow 
in the returns, and modify the fan 
pitch accordingly, to reduce ventilation 
costs. Future plans include monitoring 
the temperature and vibration df fan 
bearings, production tonnage, power 
usage, and belt operation and failure 
diagnostics. 



A similar situation exists at exam- 
ple B, where a variance has been received 
for use of beltways for intake air to 
ventilate the face because of heavy over- 
burden, roof control, and methane prob- 
lems. Because of this variance CO is 
being monitored on the beltway. Other 
parameters being monitored include bear- 
ing temperature and water gage on the 
main ventilation fans, with future plans 
for monitoring methane and airflow in the 
returns. 

At example C, the mine has extremely 
bad roof and methane gas problems. A 
chief concern is the possibility of roof 
falls that may disrupt ventilation and 
cause a methane accumulation. A seismic 
system is used to detect and locate roof 
falls through triangulation. Fan pres- 
sure, methane concentration, CO concen- 
tration, and air velocity are also being 
monitored. 



NEEDS FOR EARLY DETECTION 



Major fires and explosions in 
mines have had a fairly low frequency of 
occurrence in recent years; however, when 
they do happen, the results can be 
extremely devastating with regard to both 
loss of life and property damage. Con- 
trol of a mine fire, or dilution of an 
explosive gas, depends almost entirely 
on rapid detection, decision making, 
and communication of information to 



^Taken from a trip report of Bolt Beranek 
and Newman, Inc. , to various mines 
with monitoring systems installed. 
[U.S. Bureau of Mines (USBM) contract 
J01 00039/ "Guidelines for Environmen- 
tal Monitoring in Coal Mines." For 
more information, contact J.H. Welsh, 
Technical Project Officer, Bureau of 
Mines, Pittsburgh, Pa.] 



underground personnel. An analysis of 
the Allen report^ data (1970-77) showed 

^McDonald, L. B., and R. M. Baker. An 
Annotated Bibliography of Coal Mine 
Fire Reports. Volumes I through III. 
BuMines Open File Rept. 7(1)-(3)-80, 
Feb. 15, 1979, 1147 pp.; available for 
reference at Bureau facilities in Den- 
ver, Colo. , Twin Cities, Minn. , Pitts- 
burgh, Pa., and Spokane, Wash.; the 
National Mine Health and Safety 
Academy, Beckley, W. Va.; and National 
Library of Natural Resources, U.S. 
Dept of the Interior, Washington, D.C. 
Available from National Technical 
Information Service, Springfield, Va. , 
PB 80 — 140197 (set), PB 80 — 140205 
(v. I); PB 80 — 140213 (v. II), 
PB 140221 (v. Ill); contract JO275008, 
Allen Corp. of America. 



that a fire detected within 15 minutes of 
development resulted in no, or a minimum 
of, damage to the mine, 7 3 percent of the 
time."^ In high-volatile coal, fires over 
2 hours in duration usually involve the 
coal seam, and extinguishing the fire 
becomes very difficult. In most mines, 
miners and mining activity are absent 
from a large portion of the physical 
area, and the distance from the working 
area underground to the surface is great. 
Therefore, rapid detection and location 
of fires is very important in order to 
control the fire and provide enough time 
for miners to escape. 

As it is for fires, early detection 
of the buildup of an explosive gas is 
very important. The explosive range of 
methane is between 5 and 15 percent. The 



presence of 1.5 percent methane in the 
air current returning from active under- 
ground working places may indicate that 
considerably larger concentrations of 
methane may be accumulating in places 
through which the current of air has 
passed. In 1966, seven men lost their 
lives in an explosion in West Virginia as 
a result of electric equipment being 
energized and operated without conducting 
examinations for gas at the beginning of 
a coal-producing shift, although a pre- 
shift examination of the working places 
had been conducted within 2 hours prior 
to beginning the shift. More recently, 
in 1976 at Scotia No. 1 mine and in 1980 
at Ferrell No. 17 Mine, undetected 
accumulations of explosive gas were 
ignited, killing 26 at Scotia and 5 min- 
ers at Ferrell. 



COMPARISON OF SAFETY REGULATIONS 



Presently, mining regulations in the 
United States do not deal with the use 
of CCRMMS. Such systems may be used, in 
many cases, only as a supplement to 
existing CFR (Code of Federal Regula- 
tions) requirements, or if a lOlC peti- 
tion is granted, in lieu of existing 
requirements. In other countries, the 
safety and production benefits of CCRMMS 
are recognized, and provision is made in 
the regulations for CCRMMS. A few spe- 
cifics of the regulations of other coun- 
tries^ are given below: 

^Analysis was performed on correlation 
runs of computerized Allen Report data 
for mine fires occurring between 1970 
and 1977; analysis performed by the 
National Bureau of Standards under 
U.S. Bureau of Mines contract 
JO 100053, Systems Approach to Mine 
Fire Safety. 

^North American Mining Consult- 
ants, Inc. Single Entry Long- 
wall Study. U.S. Dept. Energy, 
contract ET-77-C-0 1-9052. 



1. Regulations in France, Poland, 
and Germany permit higher methane thresh- 
old values if constant methane monitor- 
ing is carried out by permanently 
installed recording instruments that fea- 
ture teletransmission of results, 

2. Regulations in West Germany, the 
United Kingdom, the U.S.S.R. , and Poland 
require continuous monitoring of all 
return airways from coal faces and entry 
headings by means of permanent methane 
monitoring devices, with data transmis- 
sion to central mine control stations and 
with automatic switch-off devices, 

3. Regulations in Canada and Europe 
contain safeguard monitoring measures for 
auxiliary ventilation systems based on 
automatically functioning airflow and 
methane monitors. 

4, Regulations in Germany prescribe 
the use of automatic-recording CO- 
measuring instruments in all belt 
entries. 



lOlC PETITIONS 



As mentioned previously, in order 
for a mine operator to use CCRMMS in lieu 
of applying current safety requirements, 
he must be granted a lOlC petition by 
MSHA. Several lOlC petitions that have 
been granted are briefly described 
below. 

75.305 Petitions filed under this regu- 
lation requested waiver of the 
requirement that air courses be 
examined in their entirety, 
because of hazardous roof condi- 
tions or falls. 

The petitioners want to establish 
checkpoints in the air courses where a 
person would take measurements. One 
petition requested to use a methane moni- 
tor to continuously sample the return air 
in addition to establishing air measure- 
ment stations. An audible alarm would 
alert mine personnel when the methane 
monitor detects methane above 1 percent. 

75.307 Petition requested permission to 
install a methane monitoring 
device on permissible electric 
water pximps operating in face 
areas, to monitor for methane, 
instead of having a qualified 
person make the methane tests 
just before electrical equipment 
is energized. During normal pro- 
duction shifts, when the methane 
detector-equipped pumps are oper- 
ating, methane examinations would 
be made at intervals of at least 
20 minutes, and the petitioner 
would examine for methane at 
least every 8 hours during non- 
production shifts when the pumps 
are operating. 



75.310 Petitions for variance requested 
permission to install a methane 
monitor that would continuously 
test the methane content in the 
coal mine and would automatically 
deenergize electric face equip- 
ment when the monitor is not 
operating properly or when the 
methane content reaches a speci- 
fied level (either 1.9 or 2 per- 
cent) . The sensor head is to be 
located in the split entry not 
more than 200 ft outby the face 
area in one petition, and in the 
other two, a permissible sensor 
head is to be located in the 
return aircourse of the air split 
to be monitored at a point just 
inby the location where that 
split joins another. In one 
petition, a certified person is 
still required to make frequent 
inspections of the methane moni- 
tor at least every 2 hours during 
its operation and a qualified 
person is required to make tests 
for methane in the active working 
face after each shuttle car is 
loaded, or at intervals of not 
more than 15 minutes. The other 
two petitions required weekly 
calibration and functions test 
only. Petitioner stated that the 
alternative system proposed would 
assure a reliable and constant, 
rather than intermittent, methane 
testing system during mining 
operations and would reduce the 
human failure element. The sys- 
tem would also provide a quicker 
notification time period to 
deenergize all equipment. 



75.326 Petitions requested permission to 
use the beltway to ventilate the 
active workings. By installing 
an early warning and telemetry 
system to detect CO and excessive 
heat in the belt haulage entries, 
the same measure of protection is 
provided the miners as by the 
regulation. The CO detecting 
devices must be set to monitor at 
not more than 5 ppm above ambient 
to indicate warning level, and at 
not more than 10 ppm above the 
warning level, evacuation shall 
be effected when a fire occurs in 
the belt entry. The automatic 
fire detection system must upon 
activation provide an effective 
warning signal at a manned loca- 
tion on the surface where person- 
nel have an assigned post of duty 
and have telephone or equivalent 
communication with all persons 
who may be endangered. The auto- 
matic fire detection system must 



also provide identification of 
any activated sensor. The 
detector located at or near the 
section loading point must acti- 
vate when CO is detected and 
give a warning signal that may 
be heard on the working 
section. 

75.1105 Petitions requested waiver of 
the requirement that air venti- 
lating transformer stations, 
battery charging stations, sub- 
stations, compressor stations, 
shops, and permanent pumps must 
be coursed directly into the 
return. Most of the petitioners 
wanted to add fireproof material 
and structures, fire doors, fire 
suppression devices, and some 
requested to add a remote alarm 
at a manned location, which 
would indicate the location of 
the fire so personnel under- 
ground could be notified. 



ANALYSIS OF REGULATIONS 



To determine the role of CCRMMS in 
providing an increased safety level in 
mines and to determine the relation- 
ship between mine safety regulations 
and CCRMMS, an analysis of CFR, 
Title 30, Subparts D (Ventilation) and L 
(Fire Protection) was made. The results 
are displayed in chart form in 
table 1. 



2. 
level. 



How CCRMMS affects mine safety 



3. If CCRMMS can be used in lieu of 
current requirements. 

4. Review 10 IC petitions request- 
ing use of CCRMMS in lieu of current 
requirements . 



The analysis includes: 

1. Function a CCRMMS can perform 
(both required and not required). 



It should be noted that it is 
assxmed by this analysis that the CCRMMS 
is operational, available, and accurate 
at all times. 















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CONCLUSIONS 



1. CCRMMS can perform a wide vari- 
ety of possible functions that affect 
both safety and production, 

2, CCBIMMS is capable of increasing 
the safety level in the mine since: 

(a) Monitoring is continuous 
and can detect hazards occurring in 
between periodic examinations, 

(b) Parameters not required in 
the CFR can be monitored, which may 
be site specific. 

(c) It performs diagnostic 
functions that reduce shutdown time 
on fans or other equipment critical 
to mine safety, 

(d) It provides location of 
hazards or problems, that allows for 
quick corrective action and aids in 
the escape of miners. 



(e) Detection is rapid to allow 
time for correction of hazards and 
for escape of miners, 

(f) Alarms are sent to a manned 
location on the surface, where a 




person is on duty who can communi- 
cate with personnel underground to 
notify them of the hazard and aid in 
their escape, 

3. CCRMMS can be used to perform 
CFR requirements, in lieu of certain spe- 
cific requirements, or to supplement 
these requirements. This use varies with 
each regulation, A lOlC petition must be 
granted to use CCRMMS in lieu of CFR 
requirements. 



4, 
CCRMMS: 



There are some limitations of 



It is difficult and expensive 
to design a practical CCRMMS to be 
used in high-traffic, congested 
areas such as the face. Because the 
face continuously advances, the mon- 
itoring system would have to be con- 
tinuously advanced. Design of such 
a system would require an innova- 
tive engineering effort. Regula- 
tions prohibit the use of CCRMMS in 
place of many measurement require- 
ments by specifying manual measure- 
ments; this greatly reduces cost 
benefits. 



INT.-BU.OF MINES, PGH., PA. 25984 




4s 



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